MIM Blade Heat Treatment with Jig Restraint for Shape Accuracy
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Solution Overview
Problem
In metal injection molding (MIM), high-temperature sintering and hot isostatic pressing processes can cause deformation due to thermal strain, especially in thin components, leading to dimensional inaccuracies in manufactured blades.
Innovation Solution
A blade manufacturing method involving metal injection molding, followed by a jig attaching step where the blade is sandwiched between shape-forming jigs to apply force and correct deformation, and a heat treatment step to perform heat treatment under controlled conditions, reducing thermal stress and maintaining dimensional accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a metal mold is used for blade manufacturing, then manufacturing precision and surface quality are improved, but the mold becomes contaminated with resin dust and requires frequent maintenance
Solution Approach 1:
A release film is introduced as an intermediary layer between the metal mold and the resin material. The release film prevents resin dust from contaminating the mold surface, allowing the mold to maintain high precision without frequent cleaning or maintenance. The release film is easily removable and does not leave residue on the mold.
Solution Approach 2:
The release film is designed as a disposable component that is discarded after a single use. This eliminates the need for costly and time-consuming mold maintenance while ensuring consistent blade surface quality. The low cost of the disposable release film makes this economically viable.
2Manufacturing precision
If manual demolding is used, then blade quality is maintained, but labor cost and time consumption increase
Solution Approach 1:
The mold is designed with movable components that allow automated demolding operations. The mold can open and close mechanically, enabling robots or automated systems to remove the blade without manual intervention. This maintains blade quality through controlled demolding while significantly improving productivity.
Solution Approach 2:
The mold structure incorporates self-ejecting features that automatically release the blade after curing. The blade is pushed out or released by the mold itself without requiring external manual or robotic assistance, thereby maintaining quality through consistent demolding force while maximizing manufacturing efficiency.
3Ease of manufacture
If conventional manufacturing processes are used, then existing production capabilities are maintained, but environmental pollution and resource waste occur
Solution Approach 1:
The manufacturing process transitions to using eco-friendly resin materials with modified chemical parameters that reduce pollution. The curing process parameters are optimized to minimize energy consumption and waste generation. These parameter changes maintain production capability while reducing environmental harm.
Solution Approach 2:
The manufacturing process is conducted in a controlled environment that prevents harmful emissions. The resin formulation and curing process are designed to occur without releasing volatile organic compounds or other pollutants into the atmosphere, thereby maintaining production efficiency while protecting the environment.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method ensures high dimensional accuracy of blades by minimizing thermal stress and deformation, even in components prone to temperature-induced changes, such as titanium aluminum alloys, while improving productivity and reducing manufacturing costs compared to traditional methods.
Implementation Method 1
a jig attaching step of sandwiching the blade between shape-forming surfaces of a jig which is divided into at least two parts and serves as a mold in which a shape of the blade is formed, and attaching the jig to the blade
Implementation Method 2
a heat treatment step of performing heat treatment on the blade to which the jig is attached... thermal stress that occurs in the blade can be relaxed, deformation of the blade caused by the thermal stress can be suppressed
Data Source
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AI summary
Provided is a blade manufacturing method by which a blade of a stable quality can be manufactured. The present invention involves: a shaping process in which a blade is molded by means of metal injection molding by injecting metal powder toward a mold; a jig attaching process in which a jig serving as a mold, which is divided into at least two parts forming the shape of the blade therebetween, is attached to the blade by sandwiching the blade between the shape-forming surfaces; and a thermal treatment process in which a thermal treatment is applied to the blade to which the jig has been attached.